Roll shipping container



Dec. 23, 1969 o. o. OV E iRTON m, ETAL 3,485,350

ROLL SHIPPING CONTAINER Filed June 17, 1968 3 Sheets-Sheet 1 4e r I! 2 1| I m ii"" 42A 46 4' il iiih ,4s 10- 42 ,L 1/2 20 I26 I52 I26 F/G. 2 INVENTORS DOLPHIN D. OVERTON,|I|. WILLIAM E. HUGHES RUDOLPH B. RUSTIN,JR.

ATTORNEYS e 3, 1969 D. D. OVERTON m, ETAL 3,

ROLL SHIPP ING CONTAINER 3 Sheets-Sheet 2 Filed June 17, 1968 O T R 0 D m H P L O D WlLLlAM E. HUGHES RUDOLPH B. RUSTIN,JR.

Zmeyan, M012 Qfleafiow ATTORNEYS Dec. 23, 1969 D. 0. OVERTON m, ETAL 3,

ROLL SHIPPING CONTAINER Filed June 17, 1968 3 Sheets-Sheet 5 92 FIG 5 INVENTORS I30 DOLPHIN D. OVERTON,|||.

WILLlAM E. HUGHES RUDOLPH B. RUSTIN, JR.

I26 F/ 6 d e/2 demo/z (Ra a 522a) ATTORNEYS United States Patent 0 Hughes, S.C., as- Mullins,

10 Claims ABSTRACT OF THE DISCLOSURE A shipping container is provided for one or more rolls of material wound on a hollow core. The container includes top and bottom panels, a pair of side panels, and a pair of end sections; and a pair of suspension members for each roll that fit tightly against the ends of each roll to prevent the roll from racking and that suspend the roll Within the container away from the inner surfaces of the container panels. A plurality of locking cleats are further provided on the inner surfaces of the container panels to hold the suspension members firmly against the end sections and thereby prevent longitudinal movement of the rolls within the container.

This invention relates to shipping containers, and more particularly to a shipping container for rolls of material Wound on a hollow core.

Considerable difficulty has been experienced in the past in the packaging of heavy rolls of materials, such as foil, cellophane, polyethylene, polyester, and the like. Merely placing the rolls in a container so that the rolls lie fiat on an inside surface of the container is undesirable because the rolls tend to deform under their own weight. This deformation of the roll not only interferes with its removal and subsequent use of the material but may also permanently damage the material.

It has been proposed therefore to provide shipping containers that suspend rolls of film by their ends within the container apart from the inside surfaces of the container walls to overcome some of the difficulties experienced Wtih these prior art containers.

In such containers, however, the rolls are generally only supported by their cores, permitting the material wound on the rolls to shift or rack within the container when it is subjected to impacts which invariably results in deforming or damaging the ends of the material. While preformed containers that fit tightly against the ends of the rolls will substantially prevent racking, the tight fit makes it difficult to place the rolls in the container and the packing problems become especially acute when the rolls are heavy and the container is designed to hold a plurality of rolls.

Accordingly, it is a primary object of this invention to provide a new and improved shipping container for rolls of material in which the rolls are suspended within the container to prevent deformation of the roll surfaces and in which the ends of the rolls are supported to prevent racking.

A further object of this invention is to provide a shipping container for rolls of material that prevents surface deformation or racking of the rolls and that can be quickly and easily packed and unpacked.

Still a further object of one embodiment of this invention is to provide a suspension container for rolls of material that can be quickly and easily assembled around suspended rolls of material and that supports the ends of the roll against racking when the container is assembledv 3,485,350 Patented Dec. 23, 1969 A still further object of this invention is to provide a new and improved shipping container for rolls of material that may be repeatedly re-used.

Another object of this invention it to provide strong, roll suspension containers that can withstand impacts received, during shipment and handling and can be stacked one one top of the other without damage to the containers orthe articles suspended therein.

To achieve the foregoing objects and in accordance with its purpose, this invention, as embodied and broadly described, provides a container for shipping rolls of material wound on a hollow core, in which the container includes top and bottom panels, a pair of side panels, a pair of end sections, and at least one pair of removable suspension members located at each inside end of the container, each of the members abutting the inside surface of one of the end sections and one end of the roll to prevent the roll from racking and having a plug extending into one end of the roll core to suspend the roll away from the inside surfaces of the containers panels.

In accordance with a preferred embodiment of this invention, the roll shipping container comprises two end ections, each of the end sections including a rectangular panel and a rectangular frame secured to the outer surface of the panel, the frame being slightly smaller than the panel to provide top, bottom, and side lips extending along each edge of the end section; top and bottom panels and a pair of side panels; end cleats mounted on both ends of the top, bottom, and side panels, the end cleats overlying their respective lips on the end sections and abutting the frame on the end sections; at least one pair of suspension members located at each end of the container, the suspension members including a suspension plate having an opening therein and abutting one end of the roll to prevent the roll from racking, and a removable plug that extends through said opening and into one end of the hollow core to suspend the roll at opposite ends away from the inside surfaces of the container panels; and locking cleats mounted on the inner surface of the top, bottom, and side panels, the locking cleats forming groves with the inside surfaces of the end sections for receipt of a suspension plate, the grooves having a thickness that slightly exceeds the combined thickness of the suspension plate and the flange of the tubular plug to firmly hold the plug against the end sections and preclude longitudinal movement of rolls within the container.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one embodiment of the invention, and together with the description, serve to expalin the principles of the invention.

Of the drawings:

FIG. 1 is a perspective view of the assembled container of this invention;

FIG. 2 is an end elevation of the assembled container of FIG. 1;

FIG. 3 is an exploded perspective view of the container of FIG. 1 showing the relationship between the principal parts of the container;

FIG. 4 is a sectional view taken along line 44 of FIG. 1 showing a roll of material suspended within the container;

FIG. 5 is a sectional view taken along line 55 of FIG. 4; and

FIG. 6 is a sectional view taken along line 66 of FIG. 4.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory but are not restrictive of the invention.

Reference will now be made in detail to the present preferred embodiment of this invention, an example of which is illustrated in the accompanying drawings.

As best shown in FIGS. 1 and 3, the container of this invention for packaging rolls of material includes a pair of identical end sections 10, a pair of identical side panels 14, a top panel 18, and a bottom panel 20.

End sections each include a panel 22 and a frame 24 secured to the outer surface of the panel. Frame 24 consists of a pair of upper and lower battens 26 and 28, and a pair of side battens 30 that are secured to panel 22 in any suitable manner, such as by staples or the like, to form rectangular frame 24.

As best shown in FIG. 3, frame 24 is slightly smaller than panel 22 to provide upper and lower lips 36 and 38, and side lips 40 that extend around the periphery of end section 10. The term lip, therefore, as used in the specification and claims, refers to the projecting edge of panel 22 having an abutment or shoulder at its inner end formed by frame 24.

An opening 41 is provided in each batten of frame 24 for receipt of suitable fastening means to hold the various parts of the container in assembled relationship, as will be described in more detail below.

As shown in FIGS. 1 and 3, side panels 14 are rectangular and are provided with cleats 42 at each end that extend inwardly and overlie side lips 40 on end sections 10 when the container is assembled. Similarly, rectangular top and bottom panels 18 and 20 also have cleats 44 at each end that overlie upper and lower lips 36 and 38, respectively, on end sections 10 when the container is assembled.

Cleats 42 and 44 have a width equal to the width of their respective lips on end sections 10, and thus abut against the battens of frame 24 to provide a rigid container. Preferably, the cleats are flush with the ends of the panels and of the same thickness as frame 24, so that the ends of the assembled container will have a substantially smooth outer surface.

A slot 48, as best shown in FIG. 3, is provided in each end of panels 14, 18, and 20 that extends through the panel and the cleat attached to the panel at that end and is aligned with one of the openings 41 in frame 24 when the container is assembled. Fastening means, such as tie wires 46, as shown in FIG. 1 or the like, can be inserted through slots 48 and openings 41, to hold the container in assembled relationship.

In accordance with this invention, at least one pair of removable suspension members are provided at either end of the container for supporting the ends of the roll to prevent racking and for suspending the roll within the container away from the inside surfaces of the container panels to prevent deformation of the rolls surface.

As embodied and as shown in FIGS. 3 and 4, two pairs of suspension members are provided to suspend two rolls generally 50 of material 52 wound on a hollow core 54. The suspension members, generally indicated as 56,

include a suspension plate 64 having an opening 66 therein and a removable plug 68. Plug 68 includes a tubular portion 70 and a flanged portion 72.

In assembly of the suspension member, and as best shown in FIG. 4, tubular portion 70 extends through opening 66 of plate 64 and into one end of core 54 of roll 50 so that the inner surfaces of plates 64 abut the ends of the material 52 wound on core 54 to prevent the material from racking on the core while the plugs 68 suspend the roll within the container to prevent deformation of the rolls surfaces.

As shown in FIG. 3, suspension plates 64 of the suspension members are identical in shape, and preferably square, and therefore, they can be used interchangeably at either end of the container and in any position. Suspension plates 64 can be of any strong, lightweight material, such as plywood, and plugs 68 of a strong, shear-resistant material, such as fiberboard or reinforced plastic materials.

As shown in the drawings, the container is designed to hold two rolls of material and, therefore, is provided with two pairs of suspension members. The size of the container, however, and the number of suspension members can be varied depending upon the size and number of rolls to be packaged without departing from the scope of this invention.

In accordance with a preferred embodiment of this invention, locking means are provided for holding the suspension members firmly against the inside surfaces of the end sections to prevent longitudinal movement of the rolls within the container.

As embodied, and as best shown in FIG. 3, the locking means includes locking cleats 92 that extend longitudinally along the length of both top and bottom panels 18 and 20 and similar locking cleats 94 that extend along the length of the side panels 14. Cleats 92 and 94 terminate at each end at a point spaced from the inside surface of panels 22 of end sections 10 when the container is assembled, to form grooves 103 having a thickness that slightly exceeds the combined thickness, of a suspension plate 64 and the flange 72 of a plug 68. Grooves 103 thus receive suspension plates 64 having plugs 68 inserted therein so that plug flange 72 abuts against the inside surface of panel 22 while plate 64 abuts against at least one locking cleat 92 on each of top and bottom panels 18 and 20 and against at least one locking cleat 94 on a side panel 14 to preclude longitudinal movement of the suspension member and the roll within the container.

Preferably, and as best seen in FIG. 3, two locking cleats 92 are provided on each top and bottom panel 18 and 20 and are located near the longitudinal edges of these panels. Similarly, two locking cleats 94 extend along the edges of each side panel 14 so that, and as best shown in FIG. 5, each cleat 94 abuts a cleat 92 when the container is assembled to preclude inward movement of the side panels. As further shown in FIGS. 3 and 5, an inner cleat 92' is preferably provided on top and bottom panels 18 and 20, so that at least one locking cleat contacts all four corners of the inside surface of each suspension plate 64.

The locking cleats may be of any suitable strong, lightweight material, such as wood, plywood, or a reinforced polymerized organic material and are attached to the panels by conventional fasteners, such as nails or staples.

As embodied and as shown in FIGS. 3-6, bottom panel 20 has two battens 122 that are secured to the lower surface of the panel and extend along both ends of the panel. Preferably, the outside edges of battens 122 are flush with the ends of bottom panel 20 and the ends of the battens terminate a distance short of the longitudinal edges of bottom panel 20. Each batten contains an opening to permit insertion of a tie wire 46 therethrough as best seen in FIG. 4.

As shown in FIG. 4, a plurality of skid blocks 126 are mounted on the lower surface of each corner of bottom panel 20. Skid blocks 126 are notched at 127 to receive battens 122 and include a slot 128 on the upper surface of the notched portion to permit passage of tying means, such as metal-encircling bands 130, to be placed around the top, sides, and bottom of the container adjacent its ends without interfering with the skid blocks. Bands 130 are suitably secured under tension by clips or other conventional means (not shown).

Preferably, a container manufacturer prefabricates the various elements of the container. With reference to FIG. 3, the container manufacturer would preferably attach end cleats 44 and locking cleats 92 and 92' to top and bottom panels 18 and 20; battens 122 and skid blocks 126 to bottom panel 20; end cleats 42 and locking cleats 94 to side panels 14; and frames 24 to end sections 10.

The elements of the container are then shipped to the user in knocked-down condition together with a pair of suspension members, for each roll to be packed, each member consisting of a plate 64 and a plug 68.

In one method of packaging rolls of sheet material in the container of this invention, handling means, such as a horizontally extending cantilevered bar, can be used to suspend a roll of material during the initial steps of assembling the container. In this method, a plug 68 is first inserted through opening 66 in suspension plate 64 to form a suspension member and the tubular portion 70 of the plug is then inserted into one end of the roll core. The suspension member and the roll are telescoped over the bar (not shown) and moved to the supported end of the bar with the flange 72 of plug 68 positioned adjacent the supported end of the bar. Alternatively, the suspension member may be telescoped over the bar and then the hollow core of the roll of film subsequently telescoped over the cantilevered bar and onto tubular portion 70. A second suspension member is then engaged with the other end of the roll of film while the roll is still on the bar.

The roll and suspension members are then lowered onto the upper surface of lower panel 20, so that the inside surfaces of suspension plates 64 abut an end of locking cleat 92 and one of the locking cleats 92 and the cantilevered bar is then withdrawn. The weight of the roll of sheet material is thus transferred to bottom panel 20 through roll core 54, plugs 68, and suspension plates 64 to prevent deformation of the outer surface of the roll of film.

In a similar manner, another pair of suspension members are fixed to opposite ends of another roll of film supported on a cantilevered bar, and the roll of film is then lowered onto bottom panel 20 alongside the first roll so that their axes are parallel and the plates 64 at each of the containers as shown in FIG. 5 are in abutting contact.

Once the suspension members and the rolls are in place, end sections are placed on bottom panel with lower lip 38 of each end section 10 being inserted between the two suspension plates 64 and an end cleat 44 at each end of the container so that frames 24 on end sections 10 face outwardly. In this position, the inner surface of the panels 22 of end sections 10 abuts the flanges 72 of plugs 68 so that longitudinal movement of the rolls in the container can be prevented.

Side panels 14 are then placed in position, as best shown in FIGS. 3 and 5, so that the ends of locking cleats 94 on panels 14 abut suspension plates 64 while the longitudinal edges of the lower locking cleats 94 on each panel 14 abuts a locking cleat 92 on lower panel 20.

As further shown in FIG. 3, cleats 42 at each end of panels 14 overlie side lips 40 on end sections 10 and abut the outer edge of frame 24 to provide a sturdy outer container for the rolls of material.

Alternatively, side panels 14, end sections 10, and bottom panel 20 can be preassembled, as described above, before the rolls of material are placed within the container. In this method of packaging, and after the container is assembled, a suspension member is alfixed to each end of the roll of material as described above and the roll and attached suspension members are then lowered into the open top of the preassembled container by means of a sling or other suitable handling means. As the roll is lowered into the container, plates 64 slide down in grooves 103 between the inside surface of panels 22 of end sections 10 and the end of the locking cleats 94 on one of the side panels until the bottom of plate 64 rests on bottom panel 20. p

In a similar manner, another pair of suspension members are afifixed to opposite ends of another roll and the roll is then lowered into the container alongside the first roll so the axes of the rolls are parallel and the plates 64 at each end of the container are in abutting contact as shown in FIG. 5.

The container of this invention, therefore, can be quickly and easily packed preferably by assembling the Sides and ends around rolls already suspended by the suspension members on bottom panel 20 or alternatively by preassembling the container and lowering the rolls 6 with a pair of suspension members attached to each end down into the container.

After packing the container, and as shown in FIGS. 4 and 5, plates 64 and hence rolls 50 are securely held within the container against longitudinal movement by cleats 92, 92 and 94, on the containers panels and by flanges 70 on plugs 68 which abut the inside surfaces of end sections 10. Further, plates 64 support the ends of the rolls to prevent racking and abut the containers panels and each other to also prevent lateral movement of the rolls within the container.

Finally, top panel 18 is placed on the container with the ends of locking cleats 92 on panel 18 abutting the inner surface of suspension plates 64, and the longitudinal edges of its locking cleats abutting cleats 94 on side panels 14 in a manner similar to the locking cleats on lower panel 20. In this position, end cleats 44 on top panel 18 overlie upper lips 36 and a'but frame 24 on each end section 10.

Fastening means, such as tie wires 46, as shown in FIG. 1, are then inserted through each of holes 48 in all the panels, through their adjoining cleat and through the aligned slot 41 in frames 24. The ends of the tie wires 46 are then twisted and pushed against panel 22 of end sections 10 to provide a rigid container having a smooth outer surface on all sides. Alternatively, tie wires 46 can be inserted as the individual parts of the container are being assembled.

Preferably, and as shown in FIG. 1, metal-encircling bands are placed laterally around the container adjacent its ends to prevent distortion of the assembled container during shipping or handling. As shown in FIG. 2, bands 130 pass through slots 128 in skid blocks 126 to prevent them from interfering with the blocks. Slots 128 also permit the straps to closely follow the outside configuration of the container and eliminate the excessive bridging which would result if the straps were required to go over skid blocks 126.

The invention thus provides an improved shipping container for rolls of material that suspends the rolls within the container to prevent deformation of the rolls surfaces, that prevents longitudinal or lateral movement of the rolls within the container, and that firmly supports the ends of the rolls to prevent racking of the material. Further, the invention provides a strong, durable roll shipping container that can be quickly and easily packed and unpacked or quickly and easily assembled and disassembled around the rolls of material; that permits ease in handling during shipping or storage; and that can be repeatedly reused.

The invention in its broader aspects is not limited to the specific details shown and described, and departures may be made from such details without departing from the principles of the invention and without sacrificing its chief advantages.

What is claimed is:

1. A shipping container for at least one roll of material wound on a hollow core comprising top and bottom panels, a pair of side panels, and a pair of end sections and at least one pair of suspension members located at each inside end of the container, each of said members abutting the inside surface of one of the end sections and one end of the roll to prevent the roll from racking and having a plug extending into one end of the roll core to suspend the roll away from the inside surfaces of the container panels, and grooves formed at the inner surface of at least one opposed pair of said panels, the grooves each having a thickness that permits positioning one of said suspension members in abutting relationship with the sides of the groove to prevent longitudinal movement of the roll within the container.

2. The container of claim 1, in which the grooves are formed by the inside surface of said end sections and locking cleats which extend longitudinally along the length of the inside of the side panels, the top panels, and the bottom panel.

3. The container of claim 1, wherein the suspension members include a suspension plate having an opening therein, and a removable flanged tubular plug that extends through said opening and into one end of the hollow core, the flange of said plug being located between the inner surface of one of the end sections and the outer surface of the suspension plate, with the inner surface of the suspension plate being located against an end of the roll.

4. The container of claim 2, including fastening means for securing the container in assembled relationship.

5. The container of claim 4, wherein the fastening means comprises metal-encircling bands.

6. The container of claim 1, having a palletized base for receipt of a lifting member, 7

7. A shipping container for at least one roll of material wound on a hollow core, comprising:

(a) two end sections, each of said end sections including a rectangular panel and a rectangular frame secured to the outer surface of each panel, said frame being slightly smaller than said panel to provide top, bottom, and side lips extending around each edge of the end section;

(b) top and bottom panels, and a pair of side panels,

(c) end cleats mounted on both ends of said top, bottom, and side panels, the end cleats overlying their respective lips on the end sections and abutting the frame on the end section;

(d) at least one pair of removable suspension members located at each end of the container, said suspension members including a suspension plate having an opening therein, and a removable flanged tubular plug that extends through said opening and into one end of the hollow core to suspend the roll at opposite ends away from the inside surfaces of the containers panels; the flange of said plugs being located against the outer surface of the suspension plates and the inner surface of the suspension plates being located against the ends of the roll to prevent racking; and

(6) locking cleats mounted on the inner surface of the top, bottom, and side panels, said cleats forming grooves with the inside surfaces of the end sections for receipt of the suspension plates, the grooves having a thickness that slightly exceeds the combined thickness of the suspension plate and the flange of the tubular plug to firmly hold the plug against the end sections and preclude longitudinal movement of the roll within the container.

8. The container of claim 7, wherein the locking cleats extend longitudinally along the length of the inside of the panels.

9. The container of claim 8, wherein the locking cleats on the side panels are located along its top and bottom edges and the locking cleats on the top and bottom panels are located along their side edges so that the locking cleats on adjoining panels abut one another when in assembled relationship to help strengthen the container.

10. The container of claim 7, including two pairs of suspension members for supporting and suspending two rolls at opposite ends away from each other and away from the inside surface of the container panels, the suspension plates at each end of the container abutting the container panels and each other to prevent lateral movement of the rolls within the container.

References Cited UNITED STATES PATENTS JAMES B. MARBERT, Primary Examiner 

